Gefran GFX-4 Data Sheet

Main application

• Packaging

• Extrusion

• Thermoforming

• Injection moulding

• Textile

• Multizone furnaces

GFX-4

4 LOOP MODULAR POWER CONTROLLER

Main features

4 independent loop control unit.
Compact, ready to use, equipped also with
fieldbus interface.

Unit consisting of:

• Controller

• 30, 60, 80kW solid state relay

• Current transformers (one or four)

• Fuses-holder (option)

• 4 universal main inputs

• 4 heat/cool independent PID

• 4 main output internally wired to the SSR

• 4 auxiliary analog inputs (option)

• 4 configurable output (option):
relay / logic / TRIAC / continuous

• 2 configurable relay alarm output

• 2 digital inputs

• Standard digital communication:
Modbus RTU

• Optional Fieldbus communication:
Profibus DP, CANopen, DeviceNet,
Modbus RTU, Ethernet Modbus TCP,
Ethernet IP, EtherCAT, ProfiNET

• DIN rail or panel mounting

PROFILE

GFX4 is a four independent loop control­ler, designed to manage electrical power.
GFX4 is a compact unit bounding different
technological elements like:

• controller

• solid state relay

• current transformers

• fuses-holders (option)
The final result is a cost saving in terms of
space and cabling.
GFX4 consisting of:

• power management unit

• analog and digital inputs,

• analog and digital outputs

• standard digital communication

• integrated solid state relays

• fuses-holder (option)
Geflex controls autonomously the four
loop controllers, furnishing a complete
diagnostics like the loaded current, the
control of the zones, the alarms state.
A specific step by step software tool has
been develop in order to assist the pro­duct configuration based on the different
applications.
Communication with the outside is of pri­mary importance.
Geflex dialogs with the operator terminals
according to the most popular protocols:
from the simple and efficient Modbus to,
by a second optional fieldbus communi-

cation, the by-now indispensable Profibus
DP, CANopen, DeviceNet, Modbus RTU,
Ethernet Modbus TCP, Ethernet IP,
EtherCAT, ProfiNET.

The product’s furnished with a standard

configuration, simple and quickly to modify.
The assignment of different functions to
the outputs is very simple.

MODELS

(see table in order code)

3 different sizes, depending on the elec­tric power managed, are available.

GFX4 80
Maximum contemporaneous power up to
80kW@480V.
Each zone could reach up to 19,2 kW.
This limit could be extend to 23,7 kW
using the “smart power management”
(not all the zone contemporaneous).
Nominal current 40A for zone, not con­temporary maximum 57A

GFX4 60

Maximum contemporaneous power up to
60kW@480V.
Each zone could reach up to 15,3 kW.
Nominal current 32A for zone
Fuse holder could be provide as an
option.

GFX4 30

Maximum contemporaneous power up to
30kW@480V.
Each zone could reach up to 7,6 kW.
Nominal current 16A for zone
Fuse holder could be provide as an
option.

INPUTS

Process analogue

4 universal process input could accept:
thermocouple, thermoresistance, current
and tension linear.
The type could be choose by software
and no external converting device are
required.

Digital

2 digital input.
The functionality could be selected within
a wide range including setpoint selection,
MAN/AUTO, alarm memory reset and
many other.

Incorporated CT

From 1 to 4 CT control each zone and the
relative alarm control is start up (HB..).

Auxiliary analogue (option)

4 further analogue inputs are available,
typically for external current transformer
reading.

OUTPUTS

By default a different meaning is applica­ble.

POWER

Power is controlled with double SCR in
anti-parallel, zero crossing switching prin­ciple, with configurable proportional cycle
time.
Different load connection are available:
monophase, dualphases, three-phases.

FUSES (option)

The fuses are orderable on the GFX4
30KW and 60kW model.
Thanks to this, you save time, wiring is
simplified, and dimensions in the panel
are reduced.

PROGRAMMING

The Geflex modules can be programmed:

• using GFX-OP

• using Winstrum tool software

• using Industrial PC or PLC.

The software can be used to define the
state of alarm outputs or a preset power
level to be supplied in case of broken
probe.
This assures continuity of service in the
individual zone.

Tuning

• Self-tuning:
calculation of PID parameters at system art.

• Auto-tuning continuous: continuous
adjustment of PID

• Autotuning one-shot: output modulation
and event-driven automatic PID parame­ters re-calculation

Special functions

• Soft-start: power parcellization time­based

• Software Off: disabling of the control,
outputs are turned off

• Inputs\outputs: direct management of
inputs/outputs, independently from inter­nal firmware

• Simulation of four independent Geflex
units.

Output alarms configurable via software.

Heating control

For each zone an heating control internally
connected to power unit is present, then
no further connections needed between
power unit and controller.

Cooling control (option)

For each zone a cooling control is present
4 types of outputs are available: relay,
logic, triac, continuous. A current transfor­mer is furnished with TRIAC output.

Alarms

Two relay output configurable as minimum
and maximum alarm are available for each
unit.

LEDs

Eight monitoring led are available in order
to provide diagnostic information.

RN
RUN stet of the CPU
ER
Error
DI1
DI1 digital input state
DI2
DI2 digital input state
O1
Outupt 1 state
O2
Outupt 2 state
O3
Outupt 3 state
O4
Outupt 4 state

FUNCTIONS

Control

The Geflex control algorithm works with
any type of thermal process.
Different control modes are available: from
a simple ON/OFF control to PID single or
double acting heat/cool (for cooling, simply
indicate the fluid used).
Sophisticated and efficient automatic
tuning algorithms for control parameters
provide precise process control without
the presence of an operator.

Alarms

There are 8 alarm assignable to each
single canal or to all (AND / OR logic) and
configurable as absolute, relative, direct,
reverse, window, latching or not, inhibit at
power-on.

Diagnostics

Geflex assures efficient process monito­ring from a thermal and electrical point of
view, allowing the operator to foresee bre­akdowns or malfunctions and take timely
action (for example, in case the tempe­rature safety limit is exceeded, broken
probe, load fault).
The LBA alarm precisely checks the con­trol loop, while the on-board current tran­sformer (one always present, four availa­ble in option) lets you directly monitor load
and trip the HB alarm in case of current
failure or SSR in short circuit.
Detection of short circuit or opening of
input probe, open loop alarm (LBA), inter­rupted load alarm (HB).
Over temperature alarm

STANDARD DIGITAL
COMMUNICATION

The product is furnished with standard
digital communication [PORT 1] used as
GFX4 connection to a HMI or Industrial
PC.
Also by a dedicated connector (10 pins)

it’s possible to connect the actual range

of Gefllex.
A second standard digital communication
(PORT 2) configurable by most popular
protocol:
CANopen
DeviceNet
Profibus DP
Modbus RTU
Ethernet Modbus TCP
Ethernet IP,
EtherCAT,
ProfiNET

is available as option.

Net address

Assigned by two rotative selectors.

GENERAL DESCRIPTION

3

4

5

13

6

2

12

1

7

11

10

8

9

8

14

1. DIN rail frontal

2. power terminal: screws

3. power terminal

4. ventilation grid (attention NOT obstruct)

5. hook/release device back DIN rail

6. hole for screws

7. microswitchs of configuration

8. standard digital communication

9. rotative selector switch

10. connectors J1, J2, J3, J4

11. fuses-holder (only for 30KW and 60KW models)

12. fuses-holder terminal (F1, F2, F3, F4)

13. power terminal (U1, U2, U3, U4)

14. ventilation grid (attention NOT obstruct)

DIMENSIONS - INSTALLATION

82

109,5

92,5 35 19,5

92,5 35 19,5

147

140

4

140

140

147

42140

140

111,5

182

195

101,5

109,5

4132

101,54

132 4